U.S. patent application number 10/414848 was filed with the patent office on 2004-10-21 for apparatus and method for producing colored extruded food products.
Invention is credited to Bortone, Eugenio, Hanson, Perry, Sutaria, Devang Jitendra.
Application Number | 20040206246 10/414848 |
Document ID | / |
Family ID | 33158786 |
Filed Date | 2004-10-21 |
United States Patent
Application |
20040206246 |
Kind Code |
A1 |
Bortone, Eugenio ; et
al. |
October 21, 2004 |
Apparatus and method for producing colored extruded food
products
Abstract
An apparatus and associated method for varying the color and/or
flavor of an extruded food product during a single production run
of a single extrusion device. The apparatus includes a
multi-additive injection system, which is attached to a fluid
supply line of an extrusion device. The injection system is
comprised of a plurality of additive supply tanks, which are each
in fluid communication with the fluid supply line via an injection
manifold, and a metering mechanism which selectively controls the
amount of additive injected into the supply line by each individual
supply tank. The injection system may also include a central
control mechanism for calibrating the amount of additive injected
into the supply line and for maintaining a constant fluid volume
added to the extrusion device. Each of the additive supply tanks
may contain a different colorant and/or flavoring. Two variants of
the injection manifold are provided as well as a novel injection
sequence for use with the disclosed system.
Inventors: |
Bortone, Eugenio; (Frisco,
TX) ; Hanson, Perry; (Dallas, TX) ; Sutaria,
Devang Jitendra; (Dallas, TX) |
Correspondence
Address: |
CARSTENS YEE & CAHOON, LLP
P O BOX 802334
DALLAS
TX
75380
|
Family ID: |
33158786 |
Appl. No.: |
10/414848 |
Filed: |
April 16, 2003 |
Current U.S.
Class: |
99/353 ;
99/450.2 |
Current CPC
Class: |
A23P 30/20 20160801;
B29C 2948/92657 20190201; B29C 2948/92742 20190201; B29C 48/17
20190201; A21C 11/163 20130101; B29C 2948/92828 20190201; B29C
48/08 20190201; B29C 48/175 20190201; B29C 2948/92333 20190201;
B29K 2105/0005 20130101; B29C 48/92 20190201; B29C 2948/92085
20190201; B29C 2948/92561 20190201; B29K 2105/0032 20130101; B29C
48/29 20190201; B29C 48/0022 20190201; B29C 2948/926 20190201; B29C
48/297 20190201 |
Class at
Publication: |
099/353 ;
099/450.2 |
International
Class: |
A23L 001/00 |
Claims
1. An apparatus for producing a multi-colored extruded product,
comprising in combination: (a) an extruder device having a fluid
feed port; (b) a fluid supply line in fluid communication with said
feed port; (c) an additive injection system in fluid communication
with the fluid supply line, wherein said injection system
comprises: i) a plurality of supply tanks, each of which contain a
distinctly colored additive substance, ii) an injection manifold
having a plurality of injection ports, wherein each of said
injection ports includes a conduit which connects one of said
plurality of supply tanks in fluid communication with said fluid
supply line, and iii) a metering mechanism positioned on each
conduit which selectively actuates to open or close the
conduit.
2. The apparatus of claim 1 wherein said additive injection system
further comprises: iv) a control mechanism which regulates the
actuation of each metering mechanism to open or close each conduit
in accordance with a timed sequence.
3. The apparatus of claim 1 wherein said injection ports are
arranged in a series configuration.
4. The apparatus of claim 1 wherein said injection ports are
arranged in a parallel configuration.
5. The apparatus of claim 1 wherein said metering mechanism
comprises a mechanical valve.
6. The apparatus of claim 5 wherein said mechanical valve is
manually actuated.
7. The apparatus of claim 5 wherein said mechanical valve is
electrically actuated.
8. The apparatus of claim 1 wherein said metering mechanism
comprises a pump mechanism.
9. The apparatus of claim 8 wherein said pump mechanism comprises a
peristaltic pump having an integral check valve.
10. The apparatus of claim 2 wherein said control mechanism
includes a computerized device.
11. The apparatus of claim 10 wherein said computerized device
comprises a programmable logic controller having a programmable
memory for storing an instruction to implement said timed
sequence.
12. An apparatus for producing an extruded food product having
multiple colors and flavors, comprising in combination: (a) an
extrusion device having a fluid supply inlet; (b) a fluid supply
line connected to said inlet, wherein said supply line is in fluid
communication with said inlet to a source of a fluid; (c) means for
injecting additive substances into the fluid to form an additive
solution, wherein said means comprises an additive injection system
which is in fluid communication with the fluid supply line, wherein
said injection system comprises: i) a plurality of supply tanks,
each of which contains a distinct additive substance, wherein at
least a first additive substance is a colorant and a second
additive substance is a flavoring, ii) an injection manifold having
a plurality of injection ports, wherein each of said injection
ports includes a conduit which connects one of said plurality of
supply tanks in fluid communication with said fluid supply line,
and iii) a metering mechanism positioned on each conduit which
selectively actuates to open or close the conduit.
13. The apparatus of claim 12 wherein said fluid source includes a
pump mechanism which imparts an initial flowrate to the fluid.
14. The apparatus of claim 13 wherein said additive injection
system further comprises: iv) a control mechanism linked to said
pump mechanism and to each metering mechanism, v) a flow sensor
attached downstream of said manifold which senses a resulting
flowrate of the additive solution and sends a corresponding first
signal to said control mechanism, wherein said control mechanism
regulates the actuation of each metering mechanism to open or close
each conduit in accordance with a timed sequence, and wherein said
control mechanism sends a second signal to said pump mechanism,
which, in response to said second signal, adjusts the initial
flowrate to maintain a constant resulting flowrate of the additive
solution.
15. The apparatus of claim 12 wherein said extrusion device is a
cooker extruder.
16. The apparatus of claim 12 wherein said extrusion device is a
chiller extruder.
17. The apparatus of claim 12 wherein said injection ports are
arranged in a series configuration.
18. The apparatus of claim 12 wherein said injection ports are
arranged in a parallel configuration.
19. The apparatus of claim 12 wherein said metering mechanism
comprises a mechanical valve.
20. The apparatus of claim 19 wherein said mechanical valve is
manually actuated.
21. The apparatus of claim 19 wherein said mechanical valve is
electrically actuated.
22. The apparatus of claim 12 wherein said metering mechanism
comprises a pump mechanism.
23. The apparatus of claim 22 wherein said pump mechanism comprises
a peristaltic pump having an integral check valve.
24. The apparatus of claim 14 wherein said control mechanism
includes a computerized device.
25. The apparatus of claim 24 wherein said computerized device
comprises a programmable logic controller having a programmable
memory for storing an instruction to implement said timed
sequence.
26. A system for varying the color and flavor of an extruded food
product during a single production run of an extrusion device
having a fluid supply inlet, comprising in combination: (a) a
plurality of supply tanks, each of which contains a distinct
additive substance, wherein at least a first additive substance is
a colorant and a second additive substance is a flavoring; (b) an
injection manifold having a plurality of injection ports, wherein
each of said injection ports includes a conduit which connects one
of said plurality of supply tanks in fluid communication with said
fluid supply inlet; and (c) a metering mechanism positioned on each
conduit which selectively actuates to open or close the
conduit.
27. The system of claim 26 further comprising: (d) a control
mechanism which regulates the actuation of each metering mechanism
to open or close each conduit in accordance with a timed
sequence.
28. The system of claim 26 wherein said injection ports are
arranged in a series configuration.
29. The system of claim 26 wherein said injection ports are
arranged in a parallel configuration.
30. The system of claim 26 wherein said metering mechanism
comprises a mechanical valve.
31. The system of claim 30 wherein said mechanical valve is
manually actuated.
32. The system of claim 30 wherein said mechanical valve is
electrically actuated.
33. The system of claim 26 wherein said metering mechanism
comprises a pump mechanism
34. The system of claim 33 wherein said pump mechanism comprises a
peristaltic pump having an integral check valve.
35. The apparatus of claim 27 wherein said control mechanism
includes a computerized device.
36. The apparatus of claim 35 wherein said computerized device
comprises a programmable logic controller having a programmable
memory for storing an instruction to implement said timed
sequence.
37. A method for adding a plurality of additive substances to an
extruded food product, comprising: (a) affixing an additive
injection system to a supply line, which supplies a stream of
fluid, which is admixed with a plastic food mass as the food mass
is conveyed through an extrusion device, wherein said system
comprises i) an injection manifold having a plurality of injection
ports, each comprised of a conduit which connects one of a
plurality of supply tanks in fluid communication with said fluid
supply line, wherein each supply tank contains a distinct additive
substance, and ii) a metering mechanism positioned on each conduit
which selectively actuates to open or close the conduit; (b)
selectively actuating a first metering mechanism to open a first
conduit thereby dispensing a first additive substance into said
fluid stream for a first period of time; (c) after passage of said
first period of time, selectively actuating said first metering
mechanism to close said first conduit; (d) selectively actuating a
second metering mechanism to open a second conduit thereby
dispensing a second additive substance into said fluid stream for a
second period of time; and (e) after passage of said second period
of time, selectively actuating said second metering mechanism to
close said second conduit.
38. The method of claim 37, further comprising: f) selectively
actuating a third metering mechanism to open a third conduit
thereby dispensing a third additive substance into said fluid
stream for a third period of time; and (g) after passage of said
third period of time, selectively actuating said third metering
mechanism to close said third conduit.
39. The method of claim 37, further comprising: h) selectively
actuating a fourth metering mechanism to open a fourth conduit
thereby dispensing a fourth additive substance into said fluid
stream for a fourth period of time; and (i) after passage of said
fourth period of time, selectively actuating said fourth metering
mechanism to close said fourth conduit.
40. A method for adding a plurality of additive substances to an
extruded food product, comprising: (a) affixing an additive
injection system to a supply line which supplies a stream of fluid
which is admixed with a plastic food mass as the food mass is
conveyed through an extrusion device, wherein said system comprises
i) an injection manifold having a plurality of injection ports,
each comprised of a conduit which connects one of a plurality of
supply tanks in fluid communication with said fluid supply line,
wherein each supply tank contains a distinct additive substance,
and ii) a metering mechanism positioned on each conduit which
selectively actuates to open or close the conduit; (b) injecting a
plurality of additive substances into said stream of fluid by
selectively actuating said metering mechanisms positioned on each
conduit in accordance with a repeatable injection sequence, said
sequence comprising i) actuating a first metering mechanism to open
a first conduit thereby dispensing a first additive substance into
said fluid stream for a first period of time, ii) prior to the
passage of said first period of time, actuating a second metering
mechanism to open a second conduit thereby dispensing a second
additive substance into said fluid stream for a second period of
time, iii) after passage of said first period of time, actuating
said first metering mechanism to close said first conduit, and iv)
after passage of said second period of time, actuating said second
metering mechanism to close said second conduit.
41. The method of claim 40, wherein said repeatable injection
sequence, further comprises: v) prior to the passage of said second
period of time, selectively actuating a third metering mechanism to
open a third conduit thereby dispensing a third additive substance
into said fluid stream for a third period of time, vi) prior to the
passage of said third period of time, repeating said sequence, and
vii) after passage of said third period of time, selectively
actuating said third metering mechanism to close said third
conduit.
42. The method of claim 41, wherein said first additive substance
is a yellow hued colorant, said second additive substance is a red
hued colorant, and said third additive substance is a blue hued
colorant.
43. A method for adding a plurality of additive substances to an
extruded food product, comprising: (a) affixing an additive
injection system to a supply line, which supplies a stream of
fluid, which is admixed with a plastic food mass as the food mass
is conveyed through an extrusion device, wherein said system
comprises i) an injection manifold having a plurality of injection
ports, each comprised of a conduit which connects one of a
plurality of supply tanks in fluid communication with said fluid
supply line, wherein each supply tank contains a distinct additive
substance, and ii) a metering mechanism positioned on each conduit
which selectively actuates to open or close the conduit; (b)
selectively actuating a first and second metering mechanisms to
open a first and second conduits thereby dispensing a first and
second additive substances into said fluid stream for a first
period of time; (c) after passage of said first period of time,
selectively actuating said first and second metering mechanisms to
close said first and second conduits; (d) selectively actuating a
third and fourth metering mechanisms to open a third and fourth
conduits thereby dispensing a third and fourth additive substances
into said fluid stream for a second period of time; and (e) after
passage of said second period of time, selectively actuating said
third and fourth metering mechanisms to close said third and fourth
conduits.
44. The method of claim 43, wherein said first and third additives
are distinct colorants and said second and fourth additives are
distinct flavorings.
45. A method for coloring an extruded food product, comprising: (a)
affixing an additive injection system to a supply line, which
supplies a stream of fluid, which is admixed with a plastic food
mass as the food mass is conveyed through an extrusion device,
wherein said system comprises i) an injection manifold having a
plurality of injection ports, each comprised of a conduit which
connects one of a plurality of supply tanks in fluid communication
with said fluid supply line, wherein each supply tank contains a
distinctly colored additive substance, and ii) a metering mechanism
positioned on each conduit which selectively actuates to open or
close the conduit; (b) selectively actuating in unison a first and
second metering mechanisms to simultaneously open a first and
second conduits thereby dispensing a first quantity of a first
colored additive substance and a second quantity of a second
colored additive substance into said fluid stream for a first
period of time; (c) admixing the first quantity of the first
colored additive substance and the second quantity of the second
colored additive substance in said fluid stream to form a first
colored solution in said fluid stream.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to an apparatus and method for
coloring extruded products. More particularly, the present
invention relates to a novel method and apparatus for varying the
coloring and/or flavoring of extruded food products during a single
production run of a single extrusion device.
[0003] 2. Description of the Related Art
[0004] The use of extrusion devices is prevalent in a number of
industries, especially the food industry. Because of their
versatility and efficiency, extrusion devices are often utilized to
produce a wide variety of food products such as ready-to-eat
(R-T-E) cereals, snack foods and confections. The use of extrusion
devices is particularly extensive in manufacturing food products
because a single machine can produce large quantities of finished
product in a minimal amount of time.
[0005] Food manufacturing processes which utilize extrusion devices
typically include an extruder device which receives a flowing mass
of an edible base substance and conveys it via a screw pump
mechanism to an outlet where the substance is forced through an
extruder die. Upon exiting the extruder die, the extruded substance
may be formed into sheets or cut to a desired dimension by a
cutting mechanism. The extruded substance, or extrudate, may
thereupon be further processed by, for example, freezing or
cooking.
[0006] By way of example, in FIG. 1, there is shown a simplified
schematic representation illustrating a prior art food
manufacturing process utilizing an extrusion device. As is commonly
known in the art, such a process typically includes an extrusion
device 10, which includes an inlet 12 for receiving a flowing mass
of an edible base substance; a main passageway 14, which directs
the substance to a screw pump mechanism 18, which further conveys
the substance through an extrusion chamber 16 in the direction of
arrow .di-elect cons. to an outlet 20 where the substance is forced
through an extruder die (not shown). The extrusion chamber 16 is
enclosed in an extruder casing 22. The cross-sectional area of the
extrusion chamber 16 is typically much greater than the
cross-sectional area of the outlet 20 and the extruder die.
[0007] Upon exiting the extruder die, the extruded substance may be
formed into sheets or cut to a desired dimension by a cutting
mechanism (not shown). The extrusion device 10 may also include an
additive supply line 24 which allows an additive to be introduced
to the substance prior to its conveyance through the extrusion
chamber 16 via the screw pump mechanism 18. While being conveyed
through the extrusion chamber 16 via the screw pump mechanism 18,
the additive is usually thoroughly admixed with the substance prior
to reaching outlet 20. A pump mechanism 30 is used to control the
flow rate of the additive in the direction of arrow w from a source
32 to a fluid supply inlet 26 in the extruder casing 22.
[0008] Extrusion devices may also impart or extract heat to or from
the base substance during its transit through the extruder device.
Typically, the casing 22 surrounding the extrusion chamber 16 is
adapted to impart or extract heat to or from the substance in
accordance with practices commonly known in the art. For example,
chiller extruders may be used to chill and thicken a base substance
to a desired consistency prior to its extrusion through the
extruder dies. Similarly, cooker extruders are used to prepare
cooked dough extrudates that may then be formed into individual
cereal or snack pieces, and subsequently baked or fried. One
variation of cooker extruders that is increasingly popular
comprises an extruder wherein the conditions of the extruder and
the cooked cereal dough are such that the dough puffs immediately
upon being extruded and is cut into individual puffed pieces at the
die head. Such a process is referred to generally as "direct
expansion" or "puff extrusion."
[0009] Current advances in extruder technology also make it
possible for a single extruder device to produce multiple extruded
shapes during one production run. For example, instead of using a
single extruder die, an extruder device may include a plurality of
outlet passageways that divide the original stream into multiple
sub-streams, which are each then extruded through a separate
extruder die.
[0010] While the preparation of a snack food product comprised of
multi-shaped, puffed or direct expanded extrudate is desirable, it
may also be desirable to produce a mixture of such a product that
has different colors, flavors, or similar additives. For example, a
snack food blend that includes a mixture of differently shaped
pieces may be desirable, with each shape having a distinctive color
and/or flavor. The different colors can be used to associate a
shape with a particular attribute, such as hot, very hot, savory,
sweet, etc. The coloring/flavoring of extruded food products
typically comprises either coloring and/or flavoring the base
substance prior to its introduction to the extruder device or
adding a colorant and/or flavoring to the base substance within the
extruder device wherein it is admixed utilizing the screw pump
mechanism.
[0011] In current practice, in order to produce a snack food blend
of distinctive colors, shapes or flavors, a sequence of individual
color/flavor/shape production runs are made. The product from each
run is collected and subsequently admixed to form the aggregate
blend. By way of illustration for a direct expanded snack food
product, a first cooked cereal dough is prepared by adding a first
color to the starting material or by injecting a first color into
the dough upstream of the extrusion die. The first colored dough is
directly expanded through a shaped extrusion die and face cut as it
expands to form individual pieces. To prepare a second color and
shape, the first color injection is discontinued and a second
different color material is injected into the cooked cereal dough.
To prepare a second shape, the first die head is removed and
substituted with a die head having the desired second shape.
[0012] While satisfactory, one problem with this conventional
practice resides in the generation of unusable scrap material
during the color addition transition as the new color is admixed
with the residual amounts of the prior color. Still more scrap
material is generated as the extruder comes up to steady state
conditions after the second color run is started. A second problem
is that the various colored pieces must be collected in large
batches to be admixed at a later time to form the blended snack
food product. The properties (e.g., plasticity, temperature,
moisture content, starch conditions, frangibility, etc.) of the
finished pieces may deteriorate over the storage period. A third
problem relates to the broken pieces, dust and/or cereal fines
created by the admixing step.
[0013] A variety of proposals have previously been made to remedy
the aforementioned problems associated with extrusion devices in
producing extruded food products having a blend of distinctive
shapes, colors, and/or flavors.
[0014] For example, U.S. Pat. No. 5,169,949 to Farnsworth et al.
discloses a free-standing die assembly for use in the production of
extruded products. The Farnsworth et al. '949 apparatus is mounted
as a separate unit apart from the extruder in which product
ingredients are processed. In accordance with the Farnsworth et al.
'949 invention, hot flowable dough processed in an extruder is
carried via suitable tubing to the center plate from where it is
distributed to the planar faces of the plate and into the die
units, from which it is extruded through the die orifices in the
die units. The die assembly may be modified to permit the
production of coextruded product from the die orifices in the die
units of the assembly. One or more of the die assemblies may be
associated with a single extruder. The Farnsworth et al. '949
process may also include injecting and mixing an additive into the
conduits carrying the hot flowable dough to one or both of the die
assemblies. However, while the Farnsworth et al. '949 patent
discloses a means for adding multiple colors to a common extrudate
(see e.g., FIG. 4), there are no provision for mixing or varying
pre-mixed colorants. Moreover, the Farnsworth et al. '949 device is
a fairly complex tubing and die assembly that is mounted as a
separate unit apart from the extruder in which the base product
ingredients are initially processed.
[0015] Other prior proposals include U.S. Pat. No. 5,919,509 to
Cremers et al., which discloses an apparatus and method for forming
a single extrudable food stream such as a cooked cereal dough into
a plurality of differently colored and/or flavored dough streams.
The initial plastic food mass (i.e., base substance) is divided
into a plurality of substreams by branching a main passageway
section into a plurality of sub-divided dough passageways. These
sub-passageways are each separately supplied an additive and has
disposed therein a multiplicity of in-line static mixer elements to
admix the additive into the substream of the plastic food mass
prior to extrusion through a die port. While effective, the Cremers
et al. '509 device is still rather complicated and offers no
variance of coloration/flavoring of each separate substream.
[0016] Thus, a need exists for an improved apparatus and associated
method for varying the coloring and/or flavoring of extruded food
products during a single production run of a single extrusion
device. Further, a need exists for an less complicated apparatus
and associated method for producing an extruded food product having
a blend of distinctive shapes, colors, and/or flavors during a
single production run of a single extrusion device.
SUMMARY OF THE INVENTION
[0017] The apparatus and associated method of the present invention
overcomes many of the disadvantages of prior art extrusion devices
enabling a single extrusion device to produce a multi-colored
and/or multi-flavored extruded food product during a single
production run. The improved system includes a multi-additive
injection system, which is attached to a fluid supply line of an
extrusion device. The injection system is comprised of a plurality
of additive supply tanks, which are each in fluid communication
with the fluid supply line via an injection manifold, and a
metering mechanism which selectively controls the amount of
additive injected into the supply line by each individual supply
tank. Each of the additive supply tanks may contain a different
colorant and/or flavoring. Correspondingly, each of the different
colorants and flavorings may have a different density.
Additionally, the different colorants and flavorings may be
comprised of an oil based media or emulsified compounds
[0018] The injection manifold is comprised of a tubular body having
a passageway defined therethrough and adapted to be coaxially
aligned with and fixably attached to the fluid supply line so as to
act as a passageway for a fluid passing through the fluid supply
line. The injection manifold also includes a plurality of injection
ports, which are formed in the body, and are each in fluid
communication with one of the plurality of supply tanks via an
associated additive supply line. In addition, each injection port
may include an accessory fitting to allow additive supply lines to
be quickly attached and detached. Two variants of the injection
manifold are disclosed: one with a series configuration of
injection ports, and one with a radial or parallel configuration of
injection ports.
[0019] The injection system may also include a central control
mechanism for calibrating and sequencing the amount of additive
injected into the supply line, and for maintaining a constant fluid
volume added to the extrusion device. The control mechanism may be
a mechanical or electromechanical device that is connected to the
metering mechanism and the pump mechanism, and may also include
remotely placed flow sensors. In a preferred embodiment, the
control mechanism may comprise a computerized device.
[0020] In accordance with one feature of the invention, a plurality
of colorants and/or flavorings may each be individually injected
into the fluid stream of the supply line in a sequence that results
in an extruded food product of multiple colors and flavors of the
same shape.
[0021] In accordance with another feature of the invention, two
differently hued colorants may be injected into the fluid stream of
the supply line so as to combine to form a third hued colorant that
is subsequently admixed into an extruded food product. Likewise, a
colorant and a flavoring may be in injected into the fluid stream
of the supply line so as to combine to form a flavored colorant
that is subsequently admixed into an food mass which results in an
extruded food product.
[0022] A novel feature of the invention is a repeatable color
injection sequence for use with the disclosed system wherein a
continuous flow of multi-colored extrudate may be maintained with a
minimum production of waste material, and which results in the
production of certain acceptable hues while precluding the
production of other less desirable hues,
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A more complete understanding of the method and apparatus of
the present invention may be had by reference to the following
detailed description when taken in conjunction with the
accompanying drawings, wherein:
[0024] FIG. 1 is a simplified schematic representation, not to
scale, illustrating a prior art food manufacturing process
utilizing an extrusion device;
[0025] FIG. 2 is a schematic representation, not to scale,
illustrating an embodiment of a food manufacturing process
utilizing an extrusion device and the multi-additive injection
system of the present invention;
[0026] FIG. 3 is a perspective drawing of a variant of an injection
manifold within the multi-additive injection system of the present
invention, illustrating a series arrangement of injection ports on
the injection manifold;
[0027] FIGS. 4a-4d are schematic representations, not to scale, of
the multi-additive injection system of the present invention
utilizing the injection manifold shown in FIG. 3, illustrating an
additive injection sequence;
[0028] FIG. 5a is a perspective drawing of another variant of the
injection manifold within the multi-additive injection system of
the present invention; illustrating a parallel arrangement of
injection ports on the injection manifold; and
[0029] FIG. 5b is a cross-sectional view of the injection manifold,
along line 5b-5b of FIG. 5a;
[0030] Where used in the various figures of the drawing, the same
numerals designate the same or similar parts. All figures are drawn
for ease of explanation of the basic teachings of the present
invention only; the extensions of the figures with respect to
number, position, relationship, and dimensions of the parts to form
the preferred embodiment will be explained or will be within the
skill of the art after the following teachings of the present
invention have been read and understood. Further, the exact
dimensions and dimensional proportions to conform to specific
force, weight, strength, and similar requirements will likewise be
within the skill of the art after the following teachings of the
present invention have been read and understood.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to the drawings and in particular to FIG. 2,
there is shown an embodiment of the present invention illustrating
a process and means for varying the color and/or flavor of extruded
food products during a single production run of a single extrusion
device. To more fully illustrate the general principals disclosed
in the following paragraphs, the process shown in FIG. 2 may, for
example, illustrate a direct expansion or puff extrusion process
for manufacturing a corn-based puffed product. In accordance with
such a process, a plastic food mass, such as corn meal, is directed
in a conventional manner to the inlet 112 of an extrusion device
110, wherein it is further directed via passageway 114 to a screw
pump mechanism 118. By way of example, the extrusion device 110 may
be a single (e.g., American Extrusion, Wenger, Maddox) or twin
(e.g., Wenger, Clextral, Buhler) screw-type cooker extruder such as
a model X-25 manufactured by Wenger or BC45 manufactured by
Clextral of the United States and France, respectively. A fluid
(e.g., water) may be added to the corn meal food mass via a fluid
supply line 124a-b and a fluid supply inlet 126 in the extruder
casing 122. Supply line 124a-b is in fluid communication with a
source 132 of the fluid via a pump mechanism 130. The pump
mechanism 130 may be used to control the flow rate of the fluid in
the direction of arrow w from the source 132 to a fluid supply
inlet 126 in the casing 122 of the extrusion device 110. In the
example, the water is admixed with the corn meal while in the
extrusion chamber 116 to bring the overall moisture content of the
corn meal food mass up to 15% to 18%. The corn meal becomes a
viscous melt as it approaches the outlet 120 where the corn meal
food mass is forced through an extruder die (not shown).
[0032] While transiting through the outlet 120, the viscous melt of
the food mass is subjected to high pressure and temperature, such
that the viscous melt exhibits a plastic melt phenomenon wherein
the fluidity of the melt increases as it flows through the outlet
120. As the corn meal food mass extrudate exits the outlet and
extruder die, it rapidly expands, cools, and very quickly goes from
the plastic melt stage to a glass transition stage, becoming a
relatively rigid structure, referred to as a "rod" shape if
cylindrical, puffed extrudate. This rigid rod structure can then be
cut into small pieces, further processed (e.g., baked or fried, and
seasoned) as required.
[0033] The diameter of the outlet 120 and associated extruder die
typically ranges between 2.0 mm and 12.0 mm for a corn meal
formulation at conventional moisture content, throughput rate, and
desired extrudate rod diameter or shape. However, the diameter of
outlet 120 and associated extruder die might be substantially
smaller or larger for other types of extrudate materials.
[0034] As shown in FIG. 2, the means for varying the
coloring/flavoring of the extruded food product comprises a
multi-additive injection system 140 attached to the fluid supply
line 124a-b and positioned prior to the fluid supply inlet 126 in
the casing 122 of the extrusion device 110. The injection system
140 includes a plurality of additive supply tanks (e.g., 142a-d)
which are each in fluid communication with the fluid supply line
124a-b via an injection manifold 150. Each of the plurality of
additive supply tanks (e.g., 142a-d) may contain a different
colorant and/or flavoring. The injection system 140 also includes a
metering device 144, which selectively controls the amount of
additive injected into the supply line 124a-b by each individual
supply tank. The metering device 144 may be comprised of individual
metering mechanisms attached each additive supply line (e.g.,
146a-d). For example, as illustrated in FIGS. 4a-d, the individual
metering mechanisms (e.g., 144a-d) may comprise either manually or
electrically actuated valve mechanisms. In a preferred embodiment,
the individual metering mechanisms (e.g., 144a-d) may each comprise
a peristaltic pump having an integral check valve.
[0035] It should be understood that the injection process whereby
the colorant and/or flavoring is caused to flow from its supply
tank into the stream of fluid flowing though the passageway 152a,
may be gravitationally produced or pressure induced. As is known in
the art, a positive pressure exerted on the colorant and/or
flavoring or a negative (i.e., vacuum) force created by the flowing
fluid in the passageway 152a will induce a colorant and/or
flavoring to flow from its supply tank into the fluid stream
flowing in the passageway 152a when the associated metering
mechanism is opened. In a preferred embodiment, a positive
displacement pump (e.g., peristaltic pump) positioned on the
flexible additive supply line provides a positive pressure thereby
inducing the colorant and/or flavoring to flow from its supply tank
into the stream of fluid flowing in the passageway 152a when the
associated metering mechanism is opened.
[0036] It should be further understood that the supply line 124b
downstream of the injection manifold 150 may include in-line static
mixer elements, commonly known in the art, to aid in dispersing and
mixing the various colorants/flavorings into the flowing stream of
fluid. Alternatively, the length of supply line 124b may be
minimized so as to essentially connect the injection manifold 150
directly to the fluid supply inlet 126 in the casing 122 of the
extrusion device 110 such that any mixing and dispersing of the
various colorants and flavorings is accomplished primarily by the
screw pump mechanism 118.
[0037] The process of the present invention may be further improved
with the aid of a central control mechanism 160 connected to the
metering device 144 and the pump mechanism 130. Such a control
mechanism may be used to control the sequencing of
colorants/flavorings, the time between injecting the various
colorants/flavorings, and the amount of colorant/flavoring
injected. The control mechanism may also be used to control the
flow rate of the pump mechanism 130 to ensure a constant volume of
fluid is provided to the fluid supply inlet 126 via supply line
124a-b. For example, a flow sensor device 170 may be placed
downstream of the injection manifold 150 to detect the amount of
colorant and/or flavoring injected into supply line 124a-b. Upon
sensing the injected amount, the sensor device 170 sends a signal
to the central control mechanism 130 which may, in turn, send a
signal to the pump mechanism 130 to increase or decrease the stroke
of the pump mechanism 130 in order to compensate for any volume
changes incurred due to the injection of a particular colorant or
flavoring. Thus, the multi-additive injection system 140 may be
synchronized independently from the pump mechanism 130 so as to
maintain a constant total volume of fluid supplied to the extrusion
device via the fluid supply inlet 126.
[0038] In perhaps its simplest embodiment, the central control
mechanism 160 may comprise a centralized mechanical or
electro-mechanical switchboard that may be manually operated.
However, in a preferred embodiment, the control mechanism 160 may
comprise a computerized control mechanism such as a programmable
logic controller (PLC) which includes a programmable memory for
storing instructions to implement specific functions such as logic,
injection sequence, timing, counting and arithmetic to
automatically control the multi-additive injection system 140 and
the pump mechanism 130.
[0039] Referring now, once again, to FIG. 2, the injection manifold
150 comprises a tubular body having a passageway defined
therethrough and adapted to be coaxially aligned with and fixably
attached to the supply line 124a-b so as to act as a passageway for
a fluid passing through the supply line 124a-b. The injection
manifold 150 also includes a plurality of injection ports, which
are formed in the body and generally perpendicular to the
longitudinal axis of the passageway. Each injection port provides
fluid communication between the passageway and the exterior of the
body of the injection manifold 150. Each injection port is, in
turn, in fluid communication with one of the plurality of supply
tanks (e.g., 142a-d) via an associated additive supply line (e.g.,
146a-d). Each injection port may be equipped with an accessory
fitting, which allows additive supply lines (e.g., 146a-d) to be
quickly attached and detached.
[0040] For example, as shown in FIG. 3, in one embodiment, the
injection manifold 150a comprises a generally tubular body 152
having a passageway formed therethrough which connects an inlet
port 154a in fluid communication with an outlet port 154b so as to
act as a fluid passageway for a fluid passing through the supply
line 124a-b. The inlet port 154a is adapted to be fixably attached
the supply line 124a and the outlet port 154b is adapted to be
fixably attached the supply line 124b. The manifold 150a also
includes a plurality of injection ports and their associated
accessory fittings (e.g., 156a-d) arranged along the longitudinal
axis of the tubular body 152 in a series configuration. The
accessory fittings (e.g., 156a-d) are each, in turn, connected to
an associated additive supply lines (e.g., 146a-d).
[0041] Returning now to the example process for manufacturing a
corn-based puffed product, when the entire metering device 144 is
in the closed position, the fluid (e.g., water) is supplied to the
fluid supply inlet 126 in much the same way as before. However,
when one of the individual metering mechanisms (e.g., 144a-d) is
actuated into an opened position, a colorant or flavoring may be
added and dispersed into the fluid stream prior to reaching the
inlet 126 where it is subsequently admixed with the viscous melt of
the corn meal food mass by the screw pump mechanism 118. This
process is not in and of itself novel, as it is known in the art to
inject a single colorant or flavoring into an additive supply line.
The novelty of the present invention lies in its ability to vary
the specific colorant or flavoring added to the supply line during
a single production run. This is accomplished by sequencing the
opening and closing of the various metering mechanisms (e.g.,
144a-d) so as to inject a variety of distinct colorants/flavorings
into the fluid to thereby provide an unlimited variety of colored
and flavored extruded food products during a single production run
of a single extrusion device.
[0042] By way of example, with reference now to FIGS. 4a-d,
schematic representations, not to scale, are shown which illustrate
an injection sequence of the multi-additive injection system 140 of
the present invention utilizing the variant of the injection
manifold 150a shown in FIG. 3. As stated previously, the
multi-additive injection system 140 is comprised of a plurality of
supply tanks (e.g., 142a-d), with their associated metering
mechanisms (e.g., 144a-d) and additive supply lines (e.g., 146a-d),
connected to the injection manifold 150a. The injection manifold
150a comprises a tubular body 152 having a passageway 152a formed
therethrough which is coaxially aligned with and fixably attached
to the supply line 124a-b so as to act as a passageway for a fluid
passing through the supply line 124a-b. Supply line 124a is in
fluid communication with a source of a fluid (in this case water)
which flows in the direction of arrow w. Supply line 124b is in
fluid communication with the fluid supply inlet 126 in the casing
122 of the extrusion device 110.
[0043] In the additive injection sequence which begins in FIG. 4a,
a first metering mechanism 144a is opened allowing a quantity of a
first colorant/flavoring 142a' to flow and disperse into the fluid
stream flowing through the passageway 152a in the direction of
arrow w. Referring now to FIG. 4b, to vary the coloring and/or
flavoring, after a period of time has elapsed, the first metering
mechanism 144a is closed and a second metering mechanism 144c is
opened allowing a quantity of a second colorant/flavoring 142c' to
flow and disperse the fluid stream flowing through the passageway
152a in the direction of arrow w. Likewise, as shown in FIG. 4c,
after another period of time has elapsed, the second metering
mechanism 144c is closed and a third metering mechanism 144d is
opened allowing a quantity of a third colorant/flavoring 142d' to
flow and disperse into the fluid stream flowing through the
passageway 152a in the direction of arrow w. Between the closing of
one metering mechanism and the subsequent opening another metering
mechanism, the process typically includes a time gap to allow the
preceding colorant/flavoring to be flushed past the injection point
of the subsequent colorant/flavoring thereby precluding any
unintended mixing.
[0044] On the other hand, in certain circumstances the mixing of
two or more colorants and/or flavorings might be preferred. For
example, it might be preferable to mix two colorants to form a
third colorant. Likewise, it might also be desirable to mix a
colorant with a flavoring to associate the flavoring with a
specific color. For example, it might be desirable to mix a red
hued colorant with a spicy flavoring. Conversely, it might be
preferable to mix two insoluble colorants to create a marbleized
effect in the resulting extruded product. As an example, if the
resulting extruded product is puffed and cut to form balls with
multiple colors, they may be viewed as marbles that adds play value
to the extruded food product. Similarly, in some instances it may
be preferable to inject additives comprised of insoluble granules,
oil based media or emulsified compounds for flavoring or
presentation value.
[0045] In whichever case, the desired injection and mixing may be
accomplished with the multi-additive injection system 140 of the
present invention. For example, as shown in FIG. 4d, the injection
sequence comprises opening a first metering mechanism 144d allowing
a quantity of a first colorant/flavoring 142d' to flow and disperse
into the stream of fluid flowing through the passageway 152a in the
direction of arrow w. Subsequently, a second metering mechanism
144b is opened allowing a quantity of a second colorant/flavoring
142b' to also flow and disperse into the stream of flowing fluid,
thereby combining with the first colorant/flavoring 142d' to form a
combined colorant/flavoring mixture 142b'd' which proceeds to the
fluid supply inlet 126 via supply line 124b.
[0046] Referring now to FIGS. 5a-b, an additional and preferred
embodiment of the injection manifold 150b of the multi-additive
injection system 140 of the present invention is shown. As with the
previous variant, the preferred injection manifold 150a also
comprises a generally tubular body 152 having a passageway formed
therethrough which connects an inlet port 154a in fluid
communication with an outlet port 154b so as to act as a passageway
for any fluid passing through the supply line 124a-b. The inlet
port 154a is adapted to be fixably attached the supply line 124a
and the outlet port 154b is adapted to be fixably attached the
supply line 124b. The manifold 150b also includes a plurality of
injection ports (e.g., 156a-f) and their associated accessory
fittings (e.g., 156a-f). As before, the accessory fittings (e.g.,
156a-f) are each connected to an associated additive supply lines
(e.g., 146a-f). However, instead of being arranged in a series
configuration as in the previous variant, the plurality of
injection ports (e.g., 156a-f) of the preferred injection manifold
150b are arranged in a radial or parallel configuration. While the
embodiment shown in FIG. 5a illustrates the manifold 150b with six
injection ports, it is understood that similarly configured
manifolds may have a greater or lesser number of injection ports in
accordance with design considerations.
[0047] While the previously outlined injection sequences are
applicable to the preferred variant of the injection manifold 150b,
the configuration of injection manifold 150b offers several
distinct advantages. In addition to taking up less space than
series configured manifolds with equivalent numbers of injection
ports, by reducing the internal volume of the manifold, the
preferred embodiment of the injection manifold 150b correspondingly
reduces the time gap required to flush the system between
color/flavor changes to prevent unintended mixing. Thus,
color/flavor changes may be made more rapidly and accurately.
[0048] The use of the present invention to produce a variety of
colored extruded food product during a single production run of a
single extrusion device has, in some instances, correspondingly
resulted in the necessity to create a repeatable sequence of
primary colors so as to preclude the production of certain unwanted
colors. For example, while certain hues (e.g., reds, yellows,
oranges, purples, blues and greens) are acceptable colors for
certain extruded food products, other hues (e.g., browns and
blacks) are less desirable. While the system of the present
invention provides for a flushing of one colorant from the system
prior to the introduction of a different colorant, in practice
nonetheless, precluding extended periods of flushing, it is almost
inevitable that some mixing of colorants will occur in the
extrusion device 110. It is, therefore, more efficient to create a
repeatable sequence wherein colorants may be phased in and out
without a flushing process to vary the coloration of the extruded
food product without producing the less desirable hues.
[0049] Through experimentation and analysis, a repeatable coloring
sequence process has been developed for use in conjunction with the
apparatus and method of the present invention which results in the
production of certain acceptable hues (i.e., reds, yellows,
oranges, purples, blues and greens) while precluding the production
of other less desirable hues, namely browns and blacks. For
example, the sequence may begin with a yellow hued colorant being
injected into the fluid stream which ultimately results in a
yellowed hued extrudate being produced. After a period of time, a
red hued colorant may also be gradually phased in and mixed with
the yellow hued colorant to produce varying shades of orange hued
extrudate. The yellow hued colorant may then be gradually phased
out to ultimately produce a red hued extrudate. Next, a blue hued
colorant may then be gradually phased in and mixed with the red
hued colorant to produce varying shades of purple or violet hued
extrudate. The red hued colorant may then be gradually phased out
to ultimately produce a blue hued extrudate. Finally, the yellow
hued colorant may then be gradually phased in and mixed with the
blue hued colorant to produce varying shades of a green hued
extrudate. Whereupon, the blue hued colorant may then be gradually
phased out to ultimately produce a yellow hued extrudate, at which
point the sequence begins again. In such a manner, a continuous
flow of multi-colored extrudate may be maintained with a minimum
production of waste material.
[0050] It will now be evident to those skilled in the art that
there has been described herein an improved system and associated
method for producing an extruded food product having a blend of
distinctive shapes, colors, and/or flavors during a single
production run of a single extrusion device. Moreover, the present
invention may be combined with other inventions and techniques,
known in the art of extruded food processing, to produce an
multi-colored/flavored extruded food product having multiple shapes
and imprinted lines.
[0051] It is understood that while the extrusion device 110,
preferably a cooker extruder, is the preferred equipment to provide
the extrudable corn-based puffed product used in the examples,
other conventional equipment and techniques can be employed. For
example, a batch cooker or semi-continuous cooker for cooking the
ingredients in bulk can be equipped with a dough forming and
conveying extruder element. In other embodiments, e.g., a low
moisture fruit paste or a pasta dough, a simple screw conveyor can
be employed.
[0052] Moreover, while in the present description particular
reference is made to using a cooked corn meal dough for the
preparation of a corn-based puffed product, the skilled artisan
will appreciate that the present apparatus and techniques can be
employed with a wide variety of extrudable food products,
especially such plastic foods as 1) cooked cereal doughs such as
for RTE cereals, 2) low moisture fruit products, 3) uncooked cereal
doughs such as for pasta, cookies, or breadstuffs, 4) potato doughs
such as for fabricated potato snacks, 5) chewing gums, 6) cheeses
and cheese products, or 7) yogurts.
[0053] Although the invention hereof has been described by way of a
preferred embodiment, it will be evident that other adaptations and
modifications can be employed without departing from the spirit and
scope thereof. For example, some of the steps in the system
procedure could be conducted electrically in addition to those
conducted manually. Thus, the terms and expressions employed herein
have been used as terms of description and not of limitation; and
thus, there is no intent of excluding equivalents, but on the
contrary it is intended to cover any and all equivalents that may
be employed without departing from the spirit and scope of the
invention.
* * * * *